Modeling Of Induction Heating Research Articles

An analysis of temperature control for electromagnetic induction heating of CFRP based on sparrow search algorithm

Accurate temperature control during the induction heating process of carbon fiber reinforced polymer (CFRP) is crucial for the curing effect of the material. This paper first builds a finite element model of induction heating, which combines the actual fiber structure and resin matrix, and systematically analyzes the heating mechanism and temperature field distribution of CFRP during the heating process. Based on the temperature distribution and variation observed in the material heating process, a PID control method optimized by sparrow search algorithm is proposed, which effectively reduces the temperature overshoot and improves the response speed. The experiment verifies the effectiveness of the algorithm in controlling the temperature of CFRP plate during the induction heating process. This study provides an effective control strategy and research method to improve the accuracy of temperature control in the induction heating process of CFRP, which helps to improve the results in this field.

Experimental and numerical investigations of induction heating for Ti-6Al-4V sheets and epoxy/carbon fiber composite laminates

The objective of this study is to present the electromagnetic and the thermal multi-field coupling model of the induction heating process for numerical simulation based on the finite element method. One of the most important difficulties encountered in the induction heating processes is to ensure homogeneous temperature distribution throughout the part. To improve the uniform temperature distribution in the sheet, the induction heating system is modelled with the ANSYS software taking into account some operational and geometrical parameters including current density and coupling distance between induction coil and sheet. Induction heating simulations were performed for all simulations at 20 kHz frequency ANSYS Maxwell. The numerical model has been verified by the conducted experiments for Ti6Al4V at the current of 50 A, 125 A, and 200 A, and the 1 mm and 3 mm gap distances. The relative error of the maximum temperature between the experiment and simulation was found around 14 % recorded at 25 s measurements. In addition, the effects of the current and the frequencies on the induction heating were evaluated by the verified numerical model for epoxy/carbon fiber (UD prepreg) and epoxy/carbon fiber (Woven prepreg) plates. The results show that the induction heating model is suitable and efficient to determine the temperature distribution within the thin plates by the finite element method.

Commissioning of the inductive heater for hypervapotron testing

The paper describes commissioning of the inductive heater based on numerical simulation of inductive heating in the hypervapotron sample and test channel. The HEFEL loop is being developed to research a high heat flux cooling channels applicable in fusion devices. The Box Scraper hypervapotron channel geometry represents a primary focus of research. Conditions in the first wall of tokamak are simulated by induction heating of the tested hypervapotron channel. The exact heat flux of tested sample is difficult to measure, thus the numerical simulation of induction heating and thermohydraulic model of the cooling channel are an important part of HEFEL loop commissioning. ANSYS Maxwell 3D and ANSYS Fluent coupling is used for optimalization of the induction heating to achieve the highest heat fluxes using selected induction heating source.

Effect of fibre arrangement on temperature field of CFRP induction heating

Because the characteristics of carbon fibre composites (CFRP) are directly related to the arrangement of fibre bundles, changing the orientation of fibres generates a shift in temperature field distribution during material heating. As a result, a finite element meso analysis model of CFRP induction heating is developed based on the actual laying mode and equivalent electro-magnetic thermal characteristics, and the variation laws of vortex current, calorific value, and temperature field distribution in CFRP with various fibre arrangements are simulated to investigate the role of fibre laying mode in the induction heating process. Simultaneously, the induction heating experiment shows that the finite element model developed in this paper can accurately calculate the distribution of temperature field of various types of CFRP.

Performance analysis of induction heated-porous thermochemical energy storage for heat applications in power systems

Power flexibility with fast and long-duration heat storage systems is crucial in modern power systems to meet the increasing cooling and heating demand and reduce the gap between renewable intermittent power generation and power demand. The hereby study analyzes the thermal and electrical performances of induction heated-porous thermochemical energy storage for heat applications into microgrids. The induction heating model is built with Maxwell equations for fast induction heat generation and the Surface-to-Surface (S2S) model, P1 approximation and Brinkmann model are adopted for induced and diffused heat transfer in the fluid phase and porous heat storage medium. The effects of the conductive plates’ orientation and location and the coil’s location are investigated. Furthermore, the effect of operating and structural parameters in terms of the electrical power supplied to the coil and the heat transfer coefficient of the coil’s cooling system and reactor insulation are sufficiently examined. Finally, essential parameters for the thermochemical material selection are assessed. It is found that the model with the highest magnitude of the induced magnetic flux passing through the conductive plates has outperformed at 107.57 % the worst model among the developed reactors. Moreover, the temperature distribution of the reactor resulted from the supplied power to the homogenized multi-turn coil and the heating rate at the heat storage material significantly increases with the supplied power. However, increasing the power supplied to the coil leads to higher conductive and convective heat loss resulting in less efficient electrical to heat conversion performance. Thermochemical materials with low emissivity should be preferred as the emissivity could lead to a 13.7 % improvement in the energy efficiency of the reactor. Implementing the proposed model in a microgrid for cooling and heating load improved the energy cost and self-consumption by 31.7 and 8 %, respectively.

Calculative method of effective induction heating depth and its influences on induction healing of dense-graded asphalt pavement

Induction heating technology has been widely used in the induction healing of dense-graded asphalt pavement (DGAP). It’s realized by heating the inductive materials under the electromagnetic field. The induced healing efficiency is related to the effective induction heating depth (EIHD) of inductive materials. Nevertheless, In the existing studies, the EIHD was defined by the temperature method, which is inaccurate and sensitive. Also, the relationship between EIHD and the induced healing efficiency of DGAP has not been investigated. Therefore, in this study, the heat generation and heat conduction processes of DGAP internal material were analyzed, and the EIHD was defined as the main heat generation area of inductive materials. After establishing the 2-D induction heating model of DGAP, to determine EIHD, the thermal energy of different materials in DGAP was calculated in layers by temperature measurements based on meshing. Additionally, induction heating experiments were conducted to verify the correctness of the method. At last, the relationship between EIHD and the induced healing efficiency of DGAP was found by induction healing tests. The results show that the energy-based calculative method is more accurate than the traditional temperature method. Besides, the relationship between EIHD and the overall average healing ratios of DGAP is accorded with a positive linear correlation, and the gradient healing alleviates with the increase of EIHD. This paper proposes a calculative method of EIHD in DGAP and reveals the relationship between EIHD and induced healing behaviors, which can promote the development of pavement maintenance technology.

Mathematical modeling of continuous induction heating of sour cherry juice

Induction heating is a noncontact heating method that enables heating of ferromagnetic materials. In this study, continuous induction heating system was custom set up and experimental and numerical results were compared. Sour cherry juice was heated to a target temperature value (75°C) at three different flow rates (200–250-300 ml/min) and three different set pipe wall temperatures (80–90–100°C) in experimental study. COMSOL Multiphysics 5.2 was used to solve mathematical models and visualize temperature distribution during heating and flowing. Magnetic field, heat transfer, and laminar flow physics paired each other in the model. It was concluded that the time-dependent variation of the sour cherry juice output temperature was successfully predicted by the model developed for induction process conditions. The developed models could be used to estimate process time, temperature history of materials, and effect of flow rate on heating rate any time during the continuous induction heating process. Practical applications Thermal processes applied in the food industry are aimed to inactivate the microorganisms in the food, to protect the nutrient content, and to have high energy efficiency. Conventional heating methods have a negative effect on the nutrient content of foods and the energy efficiency of the heating process due to long processing times. The advantages of induction heating are that it is a novel heating method, highly energy efficient, and performs heating process in a short time. In this study, a laboratory-scale continuous induction heating system to heat a liquid food product was established and numerical modeling of the heating process was performed. The obtained model will be an important data for installation of the continuous induction heating systems, scale-up in the continuous induction heating systems, and prediction to effects of the process parameters.

Efficiency analysis and heating structure design of high power electromagnetic thermal energy storage system

Based on the principle of electromagnetic induction, this paper proposes a new sleeve structure of electromagnetic induction heating energy storage system, which converts the electrical energy that cannot be consumed by wind power, solar power and other power grids into heat energy. The electromagnetic induction heating model of the eddy current field is established by Ansoft/Maxwell, and the magnetic induction intensity, current penetration depth and current frequency are analyzed. The three-dimensional fluid temperature field and its corresponding temperature characteristics of the system are analyzed by Ansys/Fluent. The temperature field cloud diagram of the sleeve is analyzed. It is concluded that with the increase of air thickness, the loss of the internal iron pipe increases, and the loss of the middle iron pipe decreases. The characteristic curve of the resonant circuit of the electromagnetic induction heating power supply is simulated and analyzed to determine the optimal parameters of the resonant circuit of the induction heating. A 100 kW electromagnetic energy storage system is developed, and the effectiveness and practicability of the method are verified, which can be applied to high power thermal energy storage.

Parametric optimization of removing iron from solid waste melts based on analysis of real-time coupled two-phase interface in an induction heating furnace

The removal of iron oxide impurities in aluminosilicate solid wastes is crucial to realizing the high-value utilization of solid waste. In this work, a parametric optimization method for the separation process of iron-rich phase from solid wastes driven by electromagnetic was proposed. The induction heating model of two-phase melt in the iron removal process in an electromagnetic induction furnace was established, in which the real-time coupling of electromagnetic field, temperature field, velocity field, and the two-phase interface is realized by using the level set method. Based on this numerical model, the optimal configuration for the initial volume fraction of the metal phase, current intensity, and frequency of magnetic field on the formation process of the two-phase interface and flow and heat transfer in two-phase melt were investigated. The results showed that compared with the single-phase flow, the two-phase flow is more conducive to elevating the temperature of melts. When optimizing the operational parameters, the optimal range of the initial volume fraction of the metal phase should be determined first based on the principle of fewer circulations and higher velocity in the melt. The optimal range of the initial volume fraction of the metal phase is 3%–4% in the case of this work. Then, the optimal frequency of the magnetic field corresponding to the maximum velocity can be obtained, and the appropriate current intensity can be chosen to meet the requirement of smelting in the induction furnace. The proposed parametric optimization method provides theoretical fundamentals for the configuration of the design and operating parameters of the induction furnaces.

Verification of the mathematical model of the induction soldering technological process

The paper has devoted to the research of the construction and verification of the mathematical model of the process of heating the elements of the thin-walled aluminum waveguide path in the development of the induction soldering technological procedure. The paper has reviewed the method of mathematical modeling of the induction soldering technological process. Comparative research of the induction soldering models of waveguide paths have carried out for their compliance with the real process in permissible limits. Experimental verification of the correctness of the selected mathematical model of the process of the induction soldering is performed. As a result of inventory and model experiments, it has established that the developed mathematical model of induction heating of the assembly elements of thin-wing aluminum waveguide paths of cosmic aircraft with a sufficiently high accuracy simulates this technological process.

Heat generation depth and temperature distribution in solar receiver tubes subjected to induction

Induction heating is commonly used in laboratory-scale facilities to replicate the heating conditions of the receiver tubes of concentrated solar power plants. This work aims at shedding light at the induction heating characteristics for such applications through the development of a multiphysics numerical model capable of replicating the experimental conditions of a molten salt loop locally heated by an induction heater. In the experiments, a stainless steel pipe is heated on its external surface by the induction heater, which is switched on and off during the experimental data acquisition while molten salts are continuously circulating in its interior. These conditions are replicated, for the first time, in a two-dimensional numerical domain fully coupling the electromagnetic and thermal physics, including thermally dependent material properties of the heated pipe. Once validated against the experiments, the numerical results revealed that the volumetric nature of the induction heating shall be considered for an accurate representation of the temperature profile inside the tube. As a novelty, different equivalent surface boundary conditions are presented and, despite the Gaussian-like behavior of the induction heating on the surface of the tube, the results indicate that there exists no equivalent wall boundary condition to fully replicate the temperature profile obtained with the induction heater. The effect of independently varying experimental parameters such as the geometry of the pipe (i.e., diameter and thickness) and its distance to the induction heating system is also evaluated. Using large diameters of the tube reduces the difference between the angular temperature profile obtained using induction heating and a simplified wall boundary condition. For small wall thicknesses, the induction heating is capable of penetrating along the whole thickness of the tube, the total heat generated in the volume of the tube being exposed to the counteracting effects of the volumetric generation and the enhancement of the heat dissipation by the molten salt, as both of them increase for small thicknesses. The distance of the inductor to the pipe wall appears to maintain the volumetric characteristics of the heating and only affects the induction heating magnitude and efficiency. • Fully coupled model of induction heating of a molten salt pipe is presented. • Induction promotes a volumetric heat generation in the pipe. • No equivalent surface heating can replicate induction heating. • Effect of different pipe geometries on the induction heating was characterized. • Induction reaches the whole pipe thickness for sufficiently thin tubes.

Temperature field characterization and optimization of temperature field distribution in pipe lining process based on electromagnetic induction heating system

It is a promising treatment strategy to use an induction heating system for pipe lining, which can void the low efficiency and difficult temperature control of the traditional flame and hot air heating. In this study, a novel finite element model of pipe scanning induction heating was established, and the reliability of the model was verified through experiments. In addition, through the Plackett-Burman design, the main factors affecting the temperature fluctuation at 5 mm of the lining layer are analyzed. Finally, based on the analysis results, the system parameters were optimized by response surface method and the parameter configuration of the induction heating system with the minimum temperature fluctuation of 5 mm lining layer was obtained. The model established in this paper greatly reduces the calculation time of the electromagnetic induction heating finite element model of the moving magnetic field. It can be applied to the temperature information prediction of the lining induction heating where high-temperature accuracy is required and provides a reference for the characterization of the lining induction heating system and its application in low-temperature heat treatment, and the modeling strategy can be extended to the characterization of the temperature field evolution of any mobile heat source.

Induction Heating of Gear Wheels in Consecutive Contour Hardening Process

Induction contour hardening of gear wheels belongs to effective heat treatment technologies especially recommended for high-tech applications in machinery, automotive and aerospace industries. In comparison with long term, energy consuming conventional heat treatment (carburizing and consequent quenching), its main positive features are characterized by high total efficiency, short duration and relatively low energy consumption. However, modeling of the process is relatively complicated. The numerical model should contain both multi-physic and non-linear formulation of the problem. The paper concentrates on the modeling of rapid induction heating being the first stage of the contour induction hardening process which is the time consuming part of the computations. It is taken into consideration that critical temperatures and consequently the hardening temperature are dependent on the velocity of the induction heating. Numerical modeling of coupled non-linear electromagnetic and temperature fields are shortly presented. Investigations are provided for gear wheels made of a special quality steel AISI 300M. In order to evaluate the accuracy of the proposed approach, exemplary computations of the full induction contour hardening process are provided. The exemplary results are compared with the measurements and a satisfactory accordance between them is achieved.

Thermal and electrical performance analysis of induction heating based‐thermochemical reactor for heat storage integration into power systems

In this study, the thermal and electrical performance analysis of an induction heating based-thermochemical reactor is investigated for high-temperature heat storage. The induction-heating model is built with Maxwell equations, and the surface-to-surface (S2S) radiation model is used for the induced and diffused thermal energy flow transport in the fluid phase within the reactor inner cavity. The effects of operating and structural parameters in terms of the coil turn number, coil current intensity and frequency, the conductive plate, and the coil's relative permeability, electrical conductivity, and emissivity could affect the heat generation, input power demand, and energy consumption of the proposed reactor performance are sufficiently investigated. It is found that the reactor temperature distribution resulted from the homogenized multi-turn coil magnetomotive force and frequency with the current intensity 48% more effective in reaching the desired temperature at the heat storage medium. However, the conductive plate relative permeability, electrical conductivity, and surface emissivity significantly affect the induction heating system's thermal power, with the relative permeability having the highest impact of 13% in the storage medium's temperature increasing at low current intensity. Moreover, the surface emissivity shows remarkable effects when the inducting heating operates at a high current. Significant energy consumption, more than 159%, is observed when the induction heating generator operates at steady-state mode. The reactor heating region temperature increases when the reactor operating current and frequency get high. It is observed that the more the induced heat was applied to the reactor, the more the reactor is heating up to a steady-state. The instantaneous temperature distribution inside the reactor depicted the rise in the temperature is caused by convection and radiation heat transfer. Higher and more uniform temperature distribution inside the reactor is obtained by optimizing the reactor operating and structural parameters.

Mathematical Modeling of Induction Heating of Waveguide Path Assemblies during Induction Soldering

The waveguides used in spacecraft antenna feeders are often assembled using external couplers or flanges subject to further welding or soldering. Making permanent joints by means of induction heating has proven to be the best solution in this context. However, several physical phenomena observed in the heating zone complicate any effort to control the process of making a permanent joint by induction heating; these phenomena include flux evaporation and changes in the emissivity of the material. These processes make it difficult to measure the temperature of the heating zone by means of contactless temperature sensors. Meanwhile, contact sensors are not an option due to the high requirements regarding surface quality. Besides, such sensors take a large amount of time and human involvement to install. Thus, it is a relevant undertaking to develop mathematical models for each waveguide assembly component as well as for the entire waveguide assembly. The proposed mathematical models have been tested by experiments in kind, which have shown a great degree of consistency between model-derived estimates and experimental data. The paper also shows how to use the proposed models to test and calibrate the process of making an aluminum-alloy rectangular tube flange waveguide by induction soldering. The Russian software, SimInTech, was used in this research as the modeling environment. The approach proposed herein can significantly lower the labor and material costs of calibrating and testing the process of the induction soldering of waveguides, whether the goal is to adjust the existing process or to implement a new configuration that uses different dimensions or materials.

Manifestation of the “striped heating” effect in numerical simulation of induction heating of ferromagnetic bodies near the Curie point

For the first time, the effect of “striped heating” in the induction heating of ferromagnetic materials is mentioned in the works of Soviet scientists Lozinski M.G. and Babat G.I. in the mid-20th century. They tried to give a physical explanation for the “striped heating” and expressed fears that the phenomenon might limit the use of induction hardening. However, in the practical use of induction heating in most cases, there was no significant influence of this effect on the process. In this regard, the “striped heating” was not actively discussed by the scientific community and was not sufficiently researched. The discussion on this issue was resumed by prof. Dzliev S. V. In the future, prof. Nemkov V.S. tried to gather all the available information about the “zebra effect” (as he called this phenomenon) and summarize it. This article continues the discussion about the effect of “striped heating”, and its manifestation in numerical modeling of induction heating of ferromagnetic bodies. A special case of the effect of “striped heating” in blackout induction heating with discrete overflow is given.

Modeling and Experimental Verification of Induction Heating of Thin Molybdenum Sheets

This paper deals with the issues relevant for precise finite element method (FEM) modeling of thin molybdenum plates’ induction heating. The proposed methodology describes the step-by-step Multiphysics (electro-thermal) design approach, verified by the experimental measurements. Initially, it was observed that the relative error between model and experimental set-up is within the 1.2% up to 2.5% depending on the location of the measuring points. Further research was focused on the enhancement of the simulation model in the form of its parametrization. It means that it is easy to define the induction coil’s operational parameters and geometrical properties (ferrite shape, operating frequency, the distance between plate and heating element, the value of coil current, etc.). The target of this approach is to be able to determine the optimal operational settings targeting the required heating performance of thin molybdenum plates. One of the main requirements regarding the optimal heating process is temperature distribution within the molybdenum plate’s surface. The proposed model makes it possible to obtain information on optimal operational conditions based on the received results.

Optimizing Induction Heating of WNiCo Billets Processed via Intensive Plastic Deformation

The aim of the work is to optimize the induction heating regime and propose a suitable deformation temperature for a pre-sintered powder-based tungsten heavy alloy workpiece subsequently processed via rotary swaging. The heating regime is designed with the help of numerical analyses and subsequent experiments. The first part of the study focuses on the theoretic background of the induction heating and comprises the development of a reliable induction heating model via performing electromagnetic simulations in two individual computational software packages (for verification). The second part of the study then involves the optimization of the heating regime using the designed numerical model. Last but not least, the predicted results are compared to the experimentally acquired results, and the optimized heating regime, applicable before experimental rotary swaging of the WNiCo workpiece, is proposed. The results of the microstructure analyses of the workpiece heated to the selected optimum deformation temperature of 900 °C showed that the designed induction heating procedure provided sufficient heating of the bulk of the workpiece (contrary to the lower swaging temperature), as the swaged microstructure featured well-deformed tungsten agglomerates. Furthermore, the analyses documented the high-quality oxidation-free surface of the particular workpiece (contrary to the higher swaging temperature).

Experimental and numerical study of the effect of coil structure on induction nitriding temperature field

The axial and radial temperature distributions of an induction heating workpiece considerably impact the subsequent nitriding process. To obtain a satisfactory temperature distribution, an equal pitch coil, a variable pitch coil, and a variable radius coil were designed. Furthermore, an induction heating model that exhibits electromagnetic and temperature field coupling was established; thus, the effects of the current density and frequency on the heating efficiency and temperature distribution of the workpiece were analyzed and compared. In addition, an induction heating experiment was conducted to verify the model. According to the numerical results, the variable radius coil can reduce the axial temperature difference in comparison with equal pitch coil and variable pitch coil. Hence, the workpiece heated using the variable radius coil can achieve a better temperature distribution when compared with those heated by the equal pitch coil and variable pitch coil, with appropriate current density and current frequency values.

Modeling of induction heating of thermoplastic composites

In this article, a hybrid finite element model is presented for the simulation of induction heating of layered composite plates. Modeling includes the alternating electromagnetic field generated by an alternating current running through a coil, the current densities in the composite plate resulting from the electromagnetic field, the heat generation resulting from the current density distribution, and the heat transfer resulting from the nonuniform heat generation in the plate and the temperature distribution in the plate. The different elements of the model are shown to capture the time-dependent temperature distribution resulting from a coil moving over the surface of a composite laminate.